Cable duct with punchouts

ABSTRACT

A ducting system for managing fiber optic, or other sorts of cabling. The duct has perforated circular punchouts in its sides. To drop cables to equipment below, the user simply punches out one of the circular perforated sections in the duct. This will leave a hole, which is sized to receive a downspout. Instead of punchouts, holes for the downspout could simply be drilled in the initial product. Regardless, the downspout is dropped to its full extent through and out of the duct through the hole, and is then retained by a grommet which bears against the interior of the duct. Once the downspout is secured in the hole, the selected cables are dropped from the duct through the hole, down the downspout, and into standard ribbed flex tubing, which may be force fit onto the downspout.

CROSS-REFERENCE TO RELATED APPLICATIONS

Not applicable.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

TECHNICAL FIELD

This invention relates to the field of routing, protecting, andconcealing cabling. More specifically, the present invention is relevantto the action of dropping cables from raceway duct systems.

BACKGROUND OF THE INVENTION

Raceway duct systems are used to route, protect and conceal cabling.This cabling may comprise data, voice, video, fiber optic, or powercabling. This type of duct system can have numerous configurations. Themost typical kind of ducting occurs in longitudinal sections which havea trough and a lid. There are also a variety of other types of sectionsincluded with these systems, such as 90° elbows, 45° elbow fittings,t-fittings, four way intersections (or x-sections), and others. Thesesystems often times run the cable through ducts which are run along theceiling in a facility. The type of facility referred to might be, e.g.,a telecommunications facility, or a computer equipment center office.These types of facilities often include numerous, often time hundreds orthousands of computing equipment racks. The duct work is used to deliverthe cables to the appropriate pieces of equipment in these racks.Because the cabling is run along the ceiling of such facilities, thecabling must be “dropped” to the equipment.

The prior art techniques for dropping cable to equipment from a ceilingduct system are labor intensive and costly. The most common techniqueused to accomplish this is disclosed in prior art FIG. 1. Referring tothe figure, we see a prior art fiber optic raceway system with a cabledrop assembly 10. These types of prior art systems are used to dropcabling between two standard ducts. These ducts are first standard duct12 and second standard duct 14. Each of these will be well known tothose skilled in the art as common 4 inch trough-type ducts which areusually sold in 6 foot sections. These trough sections have 4 inch sidesand a four inch floor (all in cross section). They are typicallyconstructed in durable plastic and are rather thick. In fact, they areusually manufactured with a thickness of ⅛ inch, which makes this typeof duct very durable. This protects the cable from trauma and fire. Butits thickness makes it virtually impossible to cut with a standardutility knife, or other cutting equipment which might be available totechnicians in the field.

The prior art methods involve the time consuming method of creating adrop at a junction between two existing in the ducts. Referring to FIG.1, first and second ducts, 12 and 14 respectively, are normallyconnected using a single connector.

This kind of connector is often referred to as a junction kit by thoseskilled in the art. Junction kits are used snap fit two longitudinalsections together. For example, two 6 foot sections can be snappedtogether to form a continuous 12 foot section.

Occasionally, it will be necessary to access some of the cables runningthrough the two sections and deliver them to equipment below. Thisequipment is usually located in what are known as telco or server racks.

FIG. 1 shows a prior art technique of dropping cables in such acircumstance. When it is necessary to drop a group of cables (asubcomponent of the plurality presently included in the duct) thetechnician will install a drop unit 16 in between ducts 12 and 14. Dropunit 16 is T-shaped and is used to drop the cables which have beenseparated from the bundle to be delivered to equipment below. Thedropping occurs through a lower portion 18. Lower portion 18 enables thecable to run down to the equipment, e.g., server racks, routers, andother telecommunications or computing equipment. The techniques fordoing this will be well known to those skilled in the art. T-shaped dropunits like that shown as drop unit 16 are readily available in themarket. Both ends of the “T” in junction 16 are connected to ducts 12and 14 using a first junction kit 22 and a second junction kit 24,respectively. First junction kit 22 and second junction kit 24 arecommercially available. They are each used to snap the junction inbetween the ducts. A third junction kit 26 may be used to connect thelower part of the T to a vertical duct 20. Vertical duct 20 may be usedto direct the cabling downward to protectively access it to theequipment it is designated for.

After vertical duct 20, the cabling being dropped will be inserted intowhat is known to those skilled in the art as corrugated (or ribbed)split tubing. Corrugated split tubing comes having a one inch, two inch,or sometimes even three inch inside diameter. Thus, it forms a conduithaving a smaller cross sectional smaller size than the ducts have. Thissplit tubing is also split along its length to allow access forinserting and removing cables therefrom. It is used to direct the cablesto their particular destinations in smaller bundles.

The installation of the drop cabling systems such as that shown in FIG.1 is extremely time consuming. It may take the average technician over24 hours to complete the drop of a small number of cables. This createssignificant human resource issues and costs.

Another negative is the cost of these systems. The drop unit 16, and thethree junction kits 22, 24, and 26 are somewhat expensive. Much moreexpansive than the simple straight ducting and split tubing. This inmany cases, makes the FIG. 1 process, though effective in protecting thecabling, unreasonably expensive.

Besides the FIG. 1 system, another prior art technique exists. Thisalternative system is known commercially as an Express Exit™ system. Itis sold by ADC, Inc. This ADC system lifts the selected cables, whichare intended to be dropped out from above the duct. Once the droppedcables are raised out from above the duct, they are directed tospecified equipment below in protective ducting or ribbed split tubing.The ADC product, however, has proved to be a difficult system to use.Especially in situations in which the space within the technician isallowed to work above the duct is limited. In many situations, thetechnician will be precluded from using the ADC system because there isinsufficient work space above the duct (which typically runs along theceiling of the facility). Furthermore, the installation of the ADCsystem has proven to be labor intensive, and it has significant partcosts—much like the system disclosed in FIG. 1.

Therefore, there is a need in the art for a system that is much easierand less time consuming to use, but still allows for the adequateprotection of cables being dropped out of an overhead, or otherwiseplaced duct.

SUMMARY OF THE INVENTION

The present invention overcomes the above-stated disadvantages in theprior art systems by providing a cable duct with apertures along itssides. The cable duct system of the present invention may also involvethe use of knockout sections which form the apertures. The cable ductsystem (like most) is adapted to receive a plurality of cables. The ductitself has a longitudinal floor, a first longitudinally extending side,and a second longitudinally extending side opposing the first side,wherein one of the sides or the floor define an aperture for dropping abundle of cables from the duct to equipment below it. The holes may bein the sides or floor of the duct, but preferably, are in the sidesspaced apart so that cables can optionally be dropped at differentpositions.

Another novel feature of the cable duct system of the present inventionis a downspout which is inserted through each of the holes in the duct.This downspout has first and second ends, the first end which is adaptedto be inserted through the holes provided in the ducting and then causeto depend from the ducting. The downspout is also adapted to receive andguide at least one cable there through to make the dropping of thecables more convenient. The second end of the downspout has a grommet.The grommet retains the second end of the downspout by bearing againstan internal surface of the duct. The first end of the downspout is sizedso that it can be force fit into the internal surface of a standardpiece of ribbed split tubing. Ribbed split tubing is standard in theindustry, and the forced fit enables this tubing to be suspended alongwith the downspout from the duct. The fiber optic (or other kind ofcable) is protectively held in all of these devices. The downspout canalternatively have any radius of curvature to meet the specifics of itsenvironment. In one preferred embodiment disclosed herein, however, twodownspouts are provided. One having a two-inch radius of curvature. Theother having a three-inch radius of curvature. The two different sizesmay be used together or separately to meet industry ideals.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The present invention is described in detail below with reference to theattached drawing figures, wherein:

FIG. 1 is a side view of a conventional system for dropping cable from afiber-optic cable raceway.

FIG. 2 is a side view of the duct of the present invention.

FIG. 3 is a perspective view of one end of the duct of the presentinvention in use enabling the dropping of cables to computing equipment.

FIG. 4 is an end view of one end of the duct of the present invention inuse enabling the dropping of cables to computing equipment.

FIG. 5 is a side view of one end of the duct of the present invention inuse enabling the dropping of cables to computing equipment.

DETAILED DESCRIPTION OF THE INVENTION

The present invention provides a system and method for managing thedropping of fiber-optic, or other sorts of cabling from a duct or othersystems to the equipment with minimal cost and effort.

The subject matter of the present invention is described withspecificity to meet statutory requirements. However, the descriptionitself is not intended to limit the scope of this patent. Rather, theinventors have contemplated that the claimed subject matter might alsobe embodied in other ways, to include different steps or combinations ofsteps similar to the ones described in this document, in conjunctionwith other present or future technologies. Moreover, although the term“step” may be used herein to connote different elements of methodsemployed, the term should not be interpreted as implying any particularorder among or between various steps herein disclosed unless and exceptwhen the order of individual steps is explicitly described. Further, thepresent invention is described in detail below with reference to theattached drawing figures, which are incorporated in their entirety byreference herein.

You will note the use of the terms aperture and hole throughout thisapplication. Each of these terms is to be given it's broadest meaning.The terms are intended to include any type of opening. E.g., holes,gaps, or slits would all fall within the definitions of each of theseterms. The use of either term should not be construed as imparting anyspecific shape unless otherwise specified.

FIGS. 2 through 5 show the duct system of the present invention. FIG. 2shows a side view of one section of a duct 40 of the present invention.This duct will be very similar to ducts known to those skilled in theart, except that it is provided with knockout portions (see 64 and 68)which may be physically removed by force to form apertures (not picturedin FIG. 2). These resulting apertures may be seen in FIG. 3. Referringto FIG. 3, we see the apertures 66 and 86 exist, in the depictedembodiment, in the sides of the duct. They will be used to remove anddrop cables from the duct 40 in a method to be described hereinafter.

Structurally speaking, the duct has a trough shape. As can be seen fromFIGS. 2–5, the duct 40 comprises an upper portion 42 and a lower portion44. It also has two ends 54 and 56. In cross section, the duct can beseen to have a first side 43 and a second side 45. The duct also has afloor 46 which along with sides 43 and 45 defines the trough shape ofthe duct. The bulk of the cabling will be run through the trough. Thetrough is defined by three longitudinal walls—the sides 43 and 45 andthe floor 46.

Provided on top of the duct, a lid is installed (not pictured). The lidsnaps onto and closes off the top of the trough along its entire length.It can be snapped on or off to create access to the cables included inthe trough. These lids are well known to those skilled in the art, andare the most conventional way to top off the duct. The snapping in ofthe lid is done into lid-receiving channels. A first lid receivingchannel 48 travels along the top of longitudinally extending side 45. Anidentical lid receiving channel extends along the upper part of thelongitudinally extending opposite side 43 of the duct. Channel 48 isdefined by a first ridge 50 and a second ridge 52 formed on the secondside 45 of the duct. An identical arrangement is disposed on the otherside 43 (not specifically labeled). In inwardly formed member on eachside of the lid is used to snap in on top of the duct in a fashion thatwill be well known to those skilled in the art.

Side 45 also has a first plurality of reinforcing ribs 58 and a secondplurality of reinforcing ribs 60 below the first plurality. These areused to reinforce the duct and give it more structural integrity.

In FIG. 2 it may be seen that a knock out portion 64 in side 45 isprovided by creating an outline of weakness around the portion 64 todefine it. Here, in the preferred embodiment, perforations 62 have beenused. The perforations 62 make knock out portion 64 easily removableform the ⅛ inch duct wall by a users fingers. The user simply pushesagainst portion 64 to snap it out of the duct.

It is import ant to note that other methods of weakening the duct wall,other than perforating it, could be employed to form the outline ofweakness. For example, the wall could simply be thinned out along theoutline. Chemical agents could also be employed to chemically weaken theoutline.

Alternatively still, simple holes could be drilled into the duct insteadof creating knocked out portions. These holes could simply bepre-manufactured as part of the molding process, or actively removedthrough drilling. Other cutting processes could be used instead.

Portion 64 is not the only knockout portion in the duct of the presentinvention. There are also a plurality of knocked out portions withweakened outlines 68 which run down the rest of side 45 of the duct.These knock outs are the same as portion 64.

There are also knockouts on back side 43. Though not pictured in FIG. 2,the opposite side 43 of duct 40 possesses the same kinds of knock outportions shown on side 45. formed by weakened outlines. Though these arenot pictured in FIG. 2, there are evident in FIGS. 3 through 5. Theembodiment shown in FIGS. 2 through 5 shows the same duct 40 of FIG. 2,except that the knock-out portions (alternatively preformed holes) onboth sides 43 and 45 of duct 40 have been removed.

Though FIGS. 2–5 show an embodiment in which both sides of the duct haveknockouts, it will be recognized that knockouts or simple holes could beplaced on only one side of the duct rather than both. It is alsopossible that fewer numbers or more of these knock out portions or holescould be provided on either side of the duct. Knockouts could even beprovided in the floor 46 of the duct 40.

Duct 40 of the present invention could be used alone, as it is picturedin FIG. 2 with cables being removed through the duct through the holesdirectly into split tubing and then run to the equipment as desired.

The preferred embodiment is provided, however, with optional downspouts.These downspouts are used to protectively conduct the cabling into thesplit tubing. A first downspout 70 is disclosed in FIGS. 3 through 5.This downspout has a 3 inch radius of curvature. This particular radiusof curvature enables the spout to be more practical for use in commoncable running applications. E.g., for use with particular server-rackarrangements.

Downspout 70 has essentially two parts. A grommet 71 (see FIG. 4,grommet 71 is not shown in FIGS. 3 and 5) and a spout 74. Grommet 71defines a hole through which the dropped cables will be run. This hole,though not particularly visible in the figures, is the same as a hole 79defined through an opposite downspout 77. The grommet 71 serves toretain downspout 70 into the duct from within. To do so, grommet 71bears against the inside surface of the duct to hold the downspoutwithin it. Spout 74 is used to fit through aperture 62 and includes aguide channel defined by a surface 76. The top of spout 76 has beenremoved, thus the cable or cables will be exposed above where enter intocorrugated split tubing 90 as shown. The selected fibers/cables will beslid down this channel defined by surface 76 and thus partially exposedbefore being dropped into corrugated split-tubing in a manner which willbe described hereinafter. It also protects the cable which is runthrough it.

Downspout 70 is installed into the duct by inserting a first end 75 ofthe downspout through hole 66 and sliding the downspout through the holeuntil the inside surface of grommet 71 engages the inside surface of theduct, as can be seen in FIG. 4.

FIG. 4, as well as FIGS. 3 and 5 shown that the opposite side 43 of theduct 40 includes a downspout 77 which extends from the other side of theduct. See FIG. 4. It has a grommet 72, just like grommet 71 of downspout70. In fact, downspout 77 is essentially a mirror image of downspout 70,and is installed in the same manner as well.

The spout 74 of downspout 70 has a cable receiving inside surface 76.The downspout 70 is adapted to receive the cable and drop it into asplit tubing 90 shown below. First end 71 of the spout is adapted with aradius which makes it able to be force fit within the standard insidediameter of a typical split tubing, e.g., split tubing 90. Forinstallation purposes, the downspout is slid into through hole 66, thenthe selected cables to be dropped at that point are slid down cablereceiving inside surface 76 into split tubing 90, and then an outsidesurface 78 of spout 74 is forcibly slid into the split tubing 90.Because the radius of outside surface 78 is slightly greater than theinner diameter of split tubing 90, the force fit will be enabled.

A second downspout 80 with a 2 inch radius of curvature is disclosedbeing installed through a second hole 86 in duct 40. This downspout 80,like the first downspout, will have a grommet like that disclosed fordownspout 70. Though the grommet on downspout 80 is not shown, it wouldbe the same as grommet 82 shown on a downspout opposite (in side 43).This not-pictured grommet will retain downspout 80 within the duct inthe same manner disclosed for downspout 70 already. Essentially,downspout 80 is identical to downspout 70, except that its radius ofcurvature has been minimize. This makes it more apt for differentapplications. For example, it may be advantageous with some server-rackconfigurations to drop the cabling more tightly to the duct. One skilledin the art will recognize that different radii of curvature fordifferent downspouts could be used for different kinds of applicationsin order to drop cabling at different distances from duct 40. All ofthese different curvatures and displacements should be considered withinthe scope of the present invention, and the present invention is not ofcourse limited to the two radii of curvature identified here. Otherradii or even configurations could be used and still fall within thescope of the present invention.

Though the installation techniques used with the present invention maybe already somewhat evident, they are essentially the steps of firstcreating the apertures (or knockouts) in one of said sides or floor. Youcould put the apertures anywhere. In one of the sides, or in the floor.But as can be seen in FIGS. 2–5, the preferred embodiment has holesspaced along both sides (43 and 45) of the duct 40. These holes may beformed as premanufactured or drilled holes, or as the result ofknockouts described above.

Once the duct is installed, normally at the ceiling of a facility, itwill be likely that a systems administrator will eventually have to dropgroups of cables from the duct. To do so, the user will simplyphysically remove a knockout proximate a location into which a single,or a plurality of cables need to be dropped. The knocked out portion ofthe duct, when removed, will create an aperture at the place a group ofcables is to be dropped. If the holes are premanufactured or predrilledinto the duct walls, this step will not be necessary.

After the hole has been created, in the preferred method, a downspoutwill be installed. This is done by removing the lid, if this has not yetbeen done, and then inserting the spout portion, e.g., first end 75 ofspout 70 through the aperture 66 created. The insertion is done by firstpositioning the downspout 70 such that it is curved upward. After itsfull insertion, it will then be curved downward such that it dependsfrom the duct. It will be held in by the grommet 71.

Once the downspout 70 has been fully inserted, the split tubing 90 canbe forced fit around the spout at first end 75. As described above, thisis a forced fit. The spout will then be securely held within the tubing.Tubing 90 will then be run to the equipment in a manner known to thoseskilled in the art.

Now that the spout and tubing have been installed, the user is ready torun the cable intended to be dropped. This is done by simply snaking itfrom inside the duct, though the spout, down the tubing, and to theequipment where it will be connected.

Once the necessary connections have been made, the remaining cables fromthe duct are resituated in the duct, and the lid is reinstalled. Theprocess is then complete.

Again, the ducting system of the present invention is a significantimprovement over the prior art available. The ducting of such systems istypically of such a thickness, e.g., at least ⅛ inch thick, such that itis difficult if not impossible to cut through it with a utility knife ofother tool used by a technician in the field. The knock outs, oralternatively drilled holes, enable the user to gain access at any pointalong the duct if necessary in order to drop fibers. This gives thetechnician great levity in terms of accessing different cables atdifferent points and then dropping them to equipment as desired.

As can be seen, the present invention and its equivalents are welladapted to provide a new and useful equipment housing which may be usedto monitor equipment. Many different arrangements of the variouscomponents depicted, as well as components not shown, are possiblewithout departing from the spirit and scope of the present invention.

The present invention has been described in relation to particularembodiments, which are intended in all respects to be illustrativerather than restrictive. Alternative embodiments will become apparent tothose skilled in the art that do not depart from its scope. Manyalternative embodiments exist but are not included because of the natureof this invention. A skilled programmer may develop alternative means ofimplementing the aforementioned improvements without departing from thescope of the present invention.

It will be understood that certain features and subcombinations are ofutility and may be employed without reference to other features andsubcombinations and are contemplated within the scope of the claims. Notall steps listed in the various figures need be carried out in thespecific order described.

1. A cable duct adapted to receive a plurality of fiber optic cables,said plurality including a first cable and a second cable, said ductcomprising: a longitudinal floor; a first longitudinally extending side;and a second longitudinally extending side opposing said first side;said first side defining a first aperture for dropping said first cablefrom said duct; a first curved downspout having first and second ends,the first end of said first downspout adapted to be inserted throughsaid first aperture thus causing said first downspout to depend outwardand away from said duct; said second end of said first downspout adaptedto depend from an internally positioned grommet, wherein said grommetbears against the inside surface of said duct thus retaining said firstdownspout from within said duct; and said first downspout having areceiving surface defining a guide channel, said guide channel beingadapted to receive said first cable such that said first cable is ableto be dropped down and be connected to a first piece of equipment below.2. The cable duct of claim 1 comprising: a snap-on lid for covering saidduct.
 3. The cable duct of claim 1 wherein a second aperture is definedby said second side of said duct for dropping said second cabletherefrom.
 4. The cable duct of claim 3 comprising: a second downspouthaving first and second ends, the first end of said second downspoutbeing adapted to be insertable through said second aperture and thencaused to depend from said duct, said downspout further adapted toreceive and guide said second cable to a second piece of equipmentbelow.
 5. The cable duct of claim 1, wherein said first end of saidfirst downspout is sized such that it may be force fit into an innersurface of a standard piece of ribbed split tubing.
 6. The cable duct ofclaim 1, wherein said first downspout has a 2 inch radius of curvature.7. The cable duct of claim 1, wherein said first downspout has a 3 inchradius of curvature.
 8. The cable duct of claim 1, wherein said firstdownspout has a removed upper portion which causes at least a portion ofsaid first cable to be exposed as it travels through said guide channel.9. The cable duct of claim 1, wherein each of said first and secondsides of said duct have a plurality of apertures substantially identicalto said first aperture, and each of said apertures in said plurality ofapertures has an associated downspout substantially similar to saidfirst downspout, said plurality of downspouts adapted to deliver aplurality of cables to additional equipment below.
 10. A cable ductadapted to receive a plurality of cables, said duct comprising: alongitudinal floor; a first longitudinally extending side; a secondlongitudinally extending side opposing said first side; an outline ofweakness surrounding a removable portion in one of said sides or floor,said removable portion, when removed, defining an aperture for reroutingat least one cable of said plurality from said duct using a curveddownspout; and said downspout being adapted to depend from an internallypositioned grommet and curving out and away from said duct, wherein saidgrommet bears against the inside surface of said duct thus retainingsaid downspout from within said duct.
 11. The cable duct of claim 10,wherein said outline of weakness comprises perforations.